ERNICRFE-12 Welding Wire
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ERNiCrFe-12 Welding Wire Supplier | Alloy 602 CA Filler Metal | AWS A5.14 | UNS W86025
Nicorex Alloys is an ISO 9001 and ISO 14001 certified stockist and supplier of ERNiCrFe-12 welding wire based in Mumbai, India. This wire is classified under AWS A5.14 / ASME SFA-5.14 for GTAW (TIG) and GMAW (MIG) processes.
ERNiCrFe-12 is an AWS-classified nickel alloy filler wire for high-temperature oxidation and carburisation resistance up to 1200°C (2192°F). The weld deposit has a nominal chemistry of ~62% Ni, 25% Cr, 9.5% Fe, 2.1% Al, and 0.18% C. The ~2.1% aluminium forms a self-repairing Al₂O₃ subscale beneath the primary chromium oxide layer, a feature unique among NiCrFe filler metals. Also known as Alloy 602 CA filler metal, Inconel 602CA welding wire, UNS W86025, and W.Nr. 2.4649, it uses intentionally high carbon to drive M₂₃C₆ and M₇C₃ carbide precipitation for creep strength above 1000°C, opposite to most low-carbon nickel fillers. Typical all-weld-metal tensile strength is 715 MPa (103.7 ksi) with 25% elongation. ERNiCrFe-12 TIG rods are supplied in 1000 mm cut lengths (2.0–3.2 mm dia), while MIG spools ship on D100, D200, and B300 reels (0.8–1.6 mm dia). All welding positions are supported under DC+ (DCEP) for GMAW and DC- (DCEN) for GTAW.
The primary base metal is Alloy 602 CA (UNS N06025, P-No. 43), though ERNiCrFe-12 also joins dissimilar combinations with carbon steel, stainless steel, and other nickel alloys. ERNiCrFe-12 Welding Wire is used in industries such as chemical & petrochemical, power generation, automotive and more. Every consignment from Nicorex Alloys ships with batch test certificates and MTC 3.1 per EN 10204.
ERNiCrFe-12 Welding Wire Specifications
The specifications of ERNiCrFe-12 Welding Wire, along with its AWS classification, welding process, diameters and polarity are mentioned below:
| AWS Classification | ERNiCrFe-12 |
|---|---|
| ASME SFA Specification | SFA-5.14 |
| UNS Number (Filler Wire) | W86025 |
| Welding Processes | GTAW (TIG), GMAW (MIG), PAW, SAW |
| Polarity | (GTAW): DC- (DCEN) (GMAW): DC+ (DCEP) |
| TIG Rod Diameters | 1.6, 2.0, 2.4, 3.2 mm (1/16, 5/64, 3/32 in.) |
| MIG Wire Diameters | 0.8, 0.9, 1.0, 1.2, 1.6 mm (0.030-0.045 in.) |
| TIG Rod Length | 1000 mm (39.4 in.) |
| MIG Spool Sizes | D100, D200, B300, DIN 760 reel, drums |
| Shielding Gas | (GTAW): Argon + 2.5% Nitrogen (range 1-3% N₂); back purge 100% Argon (GMAW): Cronigon® Ni 30 (Ar + ~5% N₂ + 5-10% He + trace CO₂) or equivalent |
Note: Standard pure argon shielding, used for most nickel alloy filler wires, is not suitable for ERNiCrFe-12. The 1-3% nitrogen addition to the torch gas is mandatory. It controls weld pool viscosity created by the 2.1% aluminium content and prevents porosity. The back purge gas must remain 100% argon.
Understanding the ERNiCrFe-12 AWS Classification
This section decodes the ERNiCrFe-12 AWS designation, explaining each symbol and how it links to Alloy 602 CA.
| Part of Designation | Meaning / Description |
|---|---|
| ER | Electrode/Rod – suitable as a consumable electrode for GMAW and as a rod for GTAW |
| Ni | Nickel-based alloy system |
| Cr | Chromium as a major alloying element |
| Fe | Iron as a major alloying element |
| -12 | 12th composition variant within the NiCrFe family under AWS A5.14; identifies Alloy 602 CA matching composition with ~2.1% aluminium, absent from other NiCrFe fillers |
Weld Deposit Chemical Composition of ERNiCrFe-12
The typical weld deposit chemical composition of ERNiCrFe-12 filler wire per AWS A5.14 is given below.
| Specification | Nickel (Ni) | Chromium (Cr) | Iron (Fe) | Aluminium (Al) | Carbon (C) | Titanium (Ti) | Manganese (Mn) | Silicon (Si) | Zirconium (Zr) | Sulphur (S) | Phosphorus (P) | Yttrium (Y) |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| AWS A5.14 Req. (%) | 59.0 min | 24.0–26.0 | 8.0–11.0 | 1.8–2.4 | 0.15–0.25 | 0.10–0.20 | 0.50 max | 0.50 max | 1.00 max | 0.015 max | 0.020 max | Not specified |
| Typical (%) | 62.0 | 25.0 | 9.5 | 2.1 | 0.18 | 0.14 | 0.07 | 0.04 | 0.08 | — | — | ~0.08 (trace) |
These are weld deposit values, not base metal composition. The aluminium at 1.8-2.4% forms the protective Al₂O₃ subscale that no other NiCrFe filler wire provides. The carbon at 0.15-0.25% is intentionally high. It drives M₂₃C₆ and M₇C₃ carbide precipitation for creep strength above 1000°C.
All-Weld-Metal Mechanical Properties of ERNiCrFe-12
The typical all-weld-metal mechanical properties of the ERNiCrFe-12 weld deposit are given below.
| Specification | Tensile Strength | Yield Strength (0.2% Offset) | Elongation | Impact Toughness (Charpy V-Notch) |
|---|---|---|---|---|
| Typical Value | 715 MPa (103.7 ksi) | 512 MPa (74.3 ksi) | 25% | 50 J (at room temperature) |
These are typical as-welded values at room temperature. AWS A5.14 does not mandate minimum mechanical requirements for all classifications. The yield strength of 512 MPa is unusually high for a nickel filler in the as-welded condition, reflecting the aluminium- and carbide-strengthened microstructure. The real value of ERNiCrFe-12 lies in high-temperature performance. The weld deposit maintains useful creep resistance up to 1200°C.
Base Metal Compatibility & P-Number Matrix for ERNiCrFe-12
ERNiCrFe-12 welding wire is designed primarily for joining Alloy 602 CA to itself and for dissimilar metal joints between nickel-chromium-iron alloys and steels.
| Joint Type | Base Metal 1 | P-No. | Base Metal 2 | P-No. | Filler | Notes |
|---|---|---|---|---|---|---|
| Similar | Alloy 602 CA | 43 | Alloy 602 CA | 43 | ERNiCrFe-12 | Matching chemistry, optimal oxidation resistance |
| Dissimilar | Alloy 602 CA | 43 | Alloy 601 | 43 | ERNiCrFe-12 | Preferred for service >900°C |
| Dissimilar | Alloy 602 CA | 43 | Carbon Steel | 1 | ERNiCrFe-12 | Grind all mill scale; note thermal expansion mismatch |
| Dissimilar | Alloy 602 CA | 43 | SS 304/309/310 | 8 | ERNiCrFe-12 | Consider thermal expansion differential |
| Dissimilar | Alloy 602 CA | 43 | RA 330 (800H/AT) | 45 | ERNiCrFe-12 or RA333 | 602 CA filler for highest temp service |
| Dissimilar | Alloy 602 CA | 43 | Alloy 600 | 43 | ERNiCrFe-12 or 182 | 602 CA filler preferred >1000°C |
ERNiCrFe-12 is always the recommended filler when the joint operates above ~900°C and the oxidation resistance of the weld metal is critical.
Recommended Welding Parameters for ERNiCrFe-12
The following parameters are recommended starting points for ERNiCrFe-12 welding wire. Actual parameters must be qualified per project WPS requirements.
GTAW (TIG) Parameters
| Tungsten Electrode | Polarity | Current (A) | Voltage (V) | Shielding Gas | Flow Rate |
|---|---|---|---|---|---|
| 2% Thoriated, 1.0 mm (0.040″) | DCEN | 25–80 | 10–14 | 97.5% Ar + 2.5% N₂ | 17–21 CFH |
| 2% Thoriated, 1.6 mm (0.062″) | DCEN | 50–145 | 12–16 | 97.5% Ar + 2.5% N₂ | 17–21 CFH |
| 2% Thoriated, 2.4 mm (0.094″) | DCEN | 135–235 | 12–20 | 97.5% Ar + 2.5% N₂ | 17–21 CFH |
GMAW (MIG) Parameters
| Wire Diameter | Transfer Mode | Current (A) | Voltage (V) | Shielding Gas |
|---|---|---|---|---|
| 1.14 mm (0.045″) | Spray Arc | 160–180 | 23–27 | Cronigon® Ni 30 (Ar+5%N₂+5–10%He+trace CO₂) |
SMAW (Covered Electrode ENiCrFe-12) Parameters
| Electrode Dia. | Root Pass (A) | Fill/Cap (A) | Voltage (V) | Polarity |
|---|---|---|---|---|
| 2.4 mm (3/32″) / 3.2 mm (1/8″) | 40–70 | 70–100 | 21–22 | DCEP |
| 3.2 mm (1/8″) / 4.0 mm (5/32″) | 70–100 | 90–130 | 21–22 | DCEP |
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Industrial Welding Applications of ERNiCrFe-12 Filler Metal
ERNiCrFe-12 welding wire is specified across industries where weld joints must maintain oxidation and carburisation resistance at temperatures exceeding 900°C.
- Thermal Processing & Furnace Equipment: Radiant tube welds (longitudinal seams and end cap joints), furnace muffles in bright annealing furnaces running H₂ atmosphere, kiln rollers, retort seam welds, and heat treatment baskets.
- Chemical & Petrochemical Processing: Hydrogen production reformer tube welds (steam methane reformer outlets), methanol and ammonia synthesis reactor components, cracking furnace tube joints, and catalyst support structures.
- Power Generation: Superheater and reheater tube welds in fossil fuel and waste-to-energy plants, gas turbine exhaust components, and high-temperature ducting joints.
- Automotive & Exhaust Systems: Diesel engine glow plug fabrication, high-performance exhaust components, and catalytic converter housings at extreme temperatures.
Storage, Handling & Cleaning Procedures for ERNiCrFe-12
Store TIG rods and MIG spools in a dry, temperature-controlled area in their original sealed packaging until use. Before welding, clean the base metal and filler rod with acetone to remove all oil, grease, paints, marking pencils, and thread compounds. Sulphur- and lead-bearing contaminants cause hot cracking in nickel alloy welds.
If ENiCrFe-12 covered electrodes absorb moisture, rebake at 245-300°C (475-575°F) for 2-3 hours, then hold in heated cabinets at 120-150°C. Use only stainless steel wire brushes and dedicated tooling. Carbon steel tools contaminate nickel welds with iron. After welding, brush immediately while still warm to remove heat tint.
Available Forms & Packaging of ERNiCrFe-12 Welding Wire
ERNiCrFe-12 Welding Wire is available in the following forms, diameters and packaging:
| Form | Diameter | Packaging |
|---|---|---|
| TIG Filler Rods (GTAW) | 1.6, 2.0, 2.4, 3.2 mm | 5 kg tubes |
| MIG Wire Spools (GMAW) | 0.8, 0.9, 1.0, 1.2, 1.6 mm | D100 (1 kg), D200 (5 kg), B300 (15 kg), DIN 760 reels; drums (200–250 kg) |
| Covered Electrodes (SMAW, ENiCrFe-12) | 2.4, 3.2, 4.0 mm | Hermetically sealed cans (2.5 kg, 5.0 kg) |
Standard TIG rods are supplied in 1000 mm lengths with a bright annealed surface finish. Larger drum packaging supports automated welding systems. Nicorex Alloys can also supply custom rod lengths, alternative spool sizes, and project-specific packaging upon request.
How to Order ERNiCrFe-12 Welding Wire from Nicorex Alloys
To order ERCoCr-E cobalt-chromium-molybdenum filler wire, provide the following 10 details:
- AWS Classification: ERNiCrFe-12 (wire) or ENiCrFe-12 (covered electrode)
- Product Form: TIG rod, MIG spool, covered electrode
- Diameter (mm or inch)
- Quantity (kg or number of spools/tubes)
- Spool/Reel Size: D100, D200, B300, DIN 760, drum
- Shielding Gas Requirements: Confirm nitrogen-containing gas availability
- Required Approvals: DNV, ABS, Bureau Veritas, Lloyds, TÜV, CWB
- Test Certificate Requirements: MTC 3.1 per EN 10204 (standard); additional testing if needed
- Delivery Destination: domestic (India) or export
- Packaging Preference: standard or export-grade
Nicorex Alloys can supply matching consumables across all three processes: ERNiCrFe-12 TIG rod + ERNiCrFe-12 MIG wire + ENiCrFe-12 covered electrode as a complete set for WPS qualification and production welding.
Frequently Asked Questions
Why does ERNiCrFe-12 require Nitrogen in the Shielding Gas instead of pure Argon?
Because it’s ~2.1% aluminium makes the weld pool viscous and porous in pure argon. 1-3% nitrogen in argon is needed for sound welds and a stable arc, while back purge gas must stay 100% argon.
What is the difference between ERNiCrFe-12 and ERNiCr-3 (Inconel 82) for High-Temperature Service?
ERNiCrFe-12 contains ~2.1% aluminium and 0.18% carbon, giving far better oxidation and carburisation resistance above 1000°C than ERNiCr-3, whose welds heavily oxidise on Alloy 602 CA at 1200°C.
Can ERNiCrFe-12 be used for Submerged Arc Welding (SAW)?
Yes, but two TIG cover passes are needed on the root to control aluminium burn-off, and flux compatibility must be qualified.
What Base Metals can ERNiCrFe-12 weld in Dissimilar Metal Joints?
It welds Alloy 602 CA to carbon steel (P-1), 304/309/310 stainless (P-8), Alloy 601/600 (P-43), and RA 330 / Incoloy 800H (P-45), and is preferred above 900°C.
When not to use ERNiCrFe-12 Welding Wire?
Do not use ERNiCrFe-12 Welding Wire for wet corrosion or NACE MR0175 sour service, or with pure argon shielding, and assess stress relaxation cracking risk for continuous 600-725°C service.